US1752402A - Inlaid linoleum and process of producing same - Google Patents

Description

Aprll 1, 1930. J. TOMEC ET AL INLAID LINOLEUM AND PROCESS OF PRODUCING SAME Filed July 28, 1928 Patented Apr. 1, 1930 UNITED STATES PATENT? ounce JOHN romeo AND FRANK comma, or rannz'uon, NEW JERSEY, nssreuons To w. a a

swam: MANUFACTURING comrAnr, a oonronarrou or new .rnnsnr INLAID LINOLEUM AND PROCESS 0F PRODUCING SAME Application filed July 538,

Our invention relates to a linoleum, particularly a floor covering, and process of producing the same.

Our main object is to provide an improved inlaid linoleum which has the mortar-representing or tesserae-separating portions somewhat sunk below the level of the exposed faces of the tesserae, and which shall more nearly simulate the appearance of hand-laid work.

Heretofore, linoleum had been produced with a pattern representing tiles or bricks for example with intervening diderentlycolored material representing the mortar joints, and the tiles or other t'esserae have been made to stand out in relief by indent ing the mortar-representing portions by means of ribs located on the under face of a suitable press. This method results in a product which is unsatisfactory in various particulars. For one reason, as the indenting ribs are of the same shape or cross-section throughout their length, the indentation is entirely regular, contrary to what it is in ordinary hand-laid ceramic tile floor. Also difi'iculty is often experienced in getting the indentation accurately to match with the mortar-representing material, with the result that the indentation is ofi a considerable amount,perhaps vsuilicient to cause the product to be rejected, and at leastrequiring frequent, adjustment and reregistration oithe material with reference to the ribs on the press. Also, in the case of indenting the mortar-representing portions of so-called straight line inlay material, the.

pressure may cause a breaking away between the adjoining edge of the tesserae and mortarjoint-representing material.

Our invention obviates all those objections and by it may be produced a floor or other covering which more accurately simulates the irregular appearance of hand-inlaid ceramictiling.

We are aware that various departures from the specific steps or the particular embodi ment hereafter described may he made. In the drawings, we have shown, merely as an illustrative example, parts of a linoleum 1928. Qcrial Kc. 295,861.

sheet as may be made according to our invention. i

In such drawing,

Figure 1 represents a plan view;

Figure 2 a portion in elevation before pressure is applied, and

Figure 3 a detail, partly in section and partly in perspective, of the resulting prod uct.

In Figure l, the tesserae 4, etc, such as imitation tiling for exampie, are'arranged in any desired design spaced somewhat from each other by mortar-representing portions 5 of an appearance different from the tiles.

Linoleum is a product of oxidized linseed oil, with other ingredients, usually mounted upon a burlap or other suitable backing. Linoleum has two'inain uses, as a floor coverandas a wall Qonceiling covering. When made for use as diioor covering it usually is comparatively thick and the proportion of oxidized oil to filler (granular cork or wood dust and kauri or other gum, for example) is, in the better grades, comparatively high in order to render the product highl resistant towear. When adapted for a we l covering it is not-subjected to wear in the same degree so the linoleum (such for example as the well-known lincrusta) is usually made relativelgl thin, and the proportion of the oil to the ler used is usually considerably lower. ln Figures 2 and 3, 6 represents the backing and 7 a base of linoleum material which may be formed in any desired manner, for example as ordinary single-colored linoleum is formed, i. e., by compressin the material onto the fabric backing and consolidating it by means of suitable pressure appliance, such as calendering rolls or a hydraulic press. This base sheet should be relatively soft, i. e., sufiiciently soft to allow the tesserae to be embedded therein by pressure.

The tesserae may be formed in any suitable manner and of any desired cplors or shapes. They may be cut from sheets of previously formed vari-colored linoleum, as the wellknown straight-line inlays are made. To obtain the best results, they should'be uncured, i. e. somewhat soft or malleable.

' face-weld them to the base material indicated in Figure 3, which will cause the lower-lying intervening mortar-representing material (such as at 20 in Figure 2) to flow relatively upward between-the tesserae as at 8 and 9 in Figure 3. If the pressure is relieved before the tesserae are com letely embedded in the base material, the ormer will standsomewhat in relief above the mortar-joint-representing material and give the efiect of sunken joints 1. e., of the tesserae in relief, but without the press touching such joint material.

The pressure upon the tesseree Will, if the material is sufliciently soft, cause the tesserae to be materially expanded slightly at their edges and to assume a rounded-or somewhat pointed form, as indicated for example at 10, 11 and 12 in Figure 3. This will result in the exposed faces of the 'tesserae merging somewhat adually into the mortar-representing material, as indicated for example at 12 in Figure 3. The downward pressure will of course further consolidate those portions of the base material which are underneath the tesseraa. The lateral expansion of the tessem also serves to consolidate further the intervening joint-forming portions and to cause the tesserae to be surface-welded to and in some cases interlocked with them as indicated. Of course, these shapes will not be entirely regular due to minute variations in pressure or consistency of the tesserae mate rial. This results in the mortar-representing spaces being not of the same width throughout the pattern, due to the unequal lateral expansion of the tesserae and relatively upward flow of the mortar-representing material between them. In fact regularity is not desired. Slight irregularities of tile-position, tile-outline,v joint-width .and grooveshape are desired becausethey more nearly simulate such actual irregularities in handlaid ceramic tiling. It is more artistic. This is particularly true when the irregularities do not reoccur with regularity such as in successive pattern-repeats. The trade heretofore has evinced a decided preference for linoleum made by the ordinary straight-line process-in which the tesserae are cut out of previously-consolidated sheets and assembled with their edges closely abutting-over inlays made by the moulded process because in the latter the unavoidable ragged edges between the inlays look like poor workmanship, and the raggedness occurs all around each inlay. Various expedients have been tried to hide or minimize this ragged-edge appearance and more clearly to simulate straightline efiects in goods made by the. moulded process, but such attempts have not been successful. The rag edness is still apparent. The straight-line edge, whether or not actually straig t, is preferred because it is clearly defined and so more like ceramic tiling.

A further advantage in what might be termed irregular irregularities is obtained in our product and is caused by placin the tesserae in spaced relation on the base s set, parts of which will be squeezed up between the tesserae to represent the intervenin mortar joints. Whether this locating of t e tesserae is done by hand or by automatic inlaypositioning machines, there will necessarily occur slight irre larities in location of the tesserae, but as t ere is a considerable space between them it matters not that a tile is placed somewhat askew (see tile 2 of Fig. 1) as may occur even in machine-laid tesserae. This would be a defect in an ordinary straight-line inlay in which the inlays must be placed with the edges of the inlays closely abutting each other. The unavoidable inaccuracies of hand or machine inlaying are converted into desirable artistic results. Also the unavoidable slight diiferences in softness of the tesserae may cause some of them to expand somewhat more than others. In our product the result is a desired irregular irregularity of joint width, automatically obtained.

For example, in Figure 1 the width of the space between the tesserae 2and 4 is somewhat wider than that between 1 and 4 or between tesserae 13 and 14. This more nearly simulates the actual appearance of hand-laid ceramic tiling and avoids the relatively hard and uniform and so unnatural appearance of indented-joint linoleum heretofore produced. Also when the ordinary straight-line inlaid, smooth-surfaced linoleum is by ribs indented along the joints, the somewhat shearing effect of the ribs often opens the vertical joints between inlays, resulting in a defective product which must be discarded or sold at a less price as a second. Even if the joint is not actually opened at'that time, it may be so weakened that the joint will split open when a roll of goods is opened out for laying, or after being laid, which is worse. Our product in its form illustrated needs no actual indentation of the material and avoids this step. Also the sunken joint or sunken strip between tesserae is always exactly where it ought to be. A further advantage is that the mortar-representing joints between tesserae may be made considerably narrower than would be commercially possible in either the ordinary moulded or straight-line processes.

The pressure upon the tesserae exerted by the press also may be suflicient to cause the joint-filling material, whether in the form of a sheet into which the tesseraa are bodily embedded or otherwise introduced between the tesserae, to flow relatively upward even above indicated at in Figure 2 or at 11, so

Our product, when produced as above described, results in an inlaid linoleum more closely simulating the appearance of actual hand-laid tiling in that it has various irregular irregularities usual in such a product and yet has the relatively clear-cut line of definition' between th'e edges of-the tesserm and'the mortar-representing portions which is a characteristic of the straight line inlay.

We are aware that various modifications may be made in the steps of the process as above described and in the resulting product, without departing from the scope of the invention as claimed. We. therefore, do not limit ourselves to the illustrative example above described.

What we claim is:

1. The process of producing inlaid line leum which comprises taking previously consolidated linoleum tesserae which are still malleable and arranging them in spaced relation in a desired pattern upon a sheet of some what consolidated but still soft linoleum, exerting pressure upon the exposed faces of the tesserae sufficient to embed them in and consolidate them with the base material and simultaneously laterally expand them, and relieving the pressure before the tesserae are completely embedded, thereby producing a sheet having somewhat deformed tesserae with intervening sunken spaces in which the base material is exposed to view.

2. The process of producing inlaid linoleum which comprises cutting out tesserae' from sheets of previously consolidated linoleum of the desired colors and arranging them while still malleable in spaced relation in a desired pattern upon a sheet of somewhat consolidated but still soft linoleum, ex-

erting pressure upon the exposed faces ofthe.

tesserae sufiicient to embed them in and consolidate them with the base material and simultaneously laterally expand them, and relieving the pressure before the tesserae are completely embedded, thereby producing a sheet having somewhat deformed tessera'e with intervening sunken spaces in which the base material is exposed to view.

3. The process of producing inlaidlinoleum which consists in arranging, upon a base of relatively soft linoleum, malleable linoleum tesserae separated somewhat from each other, and exerting pressure upon the exposed faces of said tesserae sufiicient to force the upper margins of said tesserae into a downwardly inclined form and the tesserae partially but not wholly into the base material, thereb leaving the intervening material at a somew at lower leveL.

4. lhe process of-producing inlaid linoleum, which comprises arranging somewhat separated linoleum tesserm upon a base of relatively soft linoleum, and exerting pres sure upon theexposed faces of the tesserae suficient to cause the base material to flow relatively upward between and around edges of the tesserae, and relieving the pressure before the base material reaches the level of the tesserm faces.

5. The leum whic process of producing inlaid linocomprises arranging in a pattern somewhat separated tesse'rae and intervening material whose exposed face is below that of adjacent tesserm, both said tesserae and filling material being-of relatively-soft linoleum, and exerting pressure upon the exposed faces of said tesserm sufiicient to expand the tesserae edges laterally and cause the intervening material to flow upwards, and relieving the pressure before the latter reaches the general level of the tesserae faces, whereby a pattern with sunken intervals is produced.

6. inlaid linoleum comprising a linoleum base with separated linoleum tesserae bodily embedded in and consolidated with the base material, the exposed faces of the tesserae standing somewhat above but gradually' merging into the intervening base material. 7. lnlaid linoleum comprising tesserae spaced somewhat and only partially'inlaid into a mortar-joint-representing linoleum material andhaving margins downwardly inclined and bodily interlocked laterally into the intervening base material.

8. An inlaid linoleum sheet comprising separatedlinoleum tesserae having substantially straight-line edges arranged in a desired pattern on and embedded only partially into, but consolidated with, a base sheet of linoleum, the intervening lower-lying base material bemg exposed to View.

9. The method of making linoleum simulating tiling, which comprises forming a foundation ayer of linoleum composition of substantial thickness and homogeneity extending continuously throughout the area of the intended product; forming separate inlays'of linoleum compositiomeach simulating. a tile; preparing the foundation layer and inlays to present plastic surface-portions capable of being welded together and integrated under pressure, and of permitting the inlays to be impressed into the surface of the foundation layer, and of permitting surfaceportions of the latter to flow somewhat under pressure; assembling inlays in substantially nonscontiguous relationships in imitation of the arrangement of tiling, upon the plastic surface of the foundation layer, so

that areas of the latter remain exposed between inlays to simulate mortar, joints in I of the product, whereby said stratum supplies a tough, durable, integral body for the product,- independently of the bonds between the inlays and the foundation layer.

10. The method of making linoleum which comprises forming a foundation layer of linoleum composition of substantial thickness and homogeneity extending continuously throughout the area of the intended product, and havin plastic surface-portions capable of permittlng inlays to be impressed into the surface of the foundation layer, and of permittin surface-portions of the latter to flow somew at under pressure; assembling inlays in substantially non-contiguous vrelationships upon the plastic surface ofthe foundation layer so that areas of the latter remain exposed between inlays; applying pressure to impress the inlays into the surface of the foundation layer, and to cause part of the foundation layer to flow into spaces between inlays; and governing the pressure to predetermine the extent to which the inlays are impressed into the surface of the foundation layer and to produce different surface levels of the inlays and those areas of the foundation layer that intervene between inlays, while preserving beneath the inlays collectively a substantially continuous, integral and homogeneous stratum of the foundationlayer material throughout the intended area of the roduct, whereby said stratum supplies a toug durable, integral body for the product, independently of the inlays.

11. The method of making linoleum which comprises forming a foundation layer of linoleum composition; forming separate inlays of linoleum composition; preparing the foundation layer and inlays to present plastic surface-portions capable of being welded together and integrated under pressure, and of permitting the inlays to be impressed into the surface of the foundation layer, and of permitting surface-portions of the latter to flow somewhat under pressure; assembling inlays in substantially non-contiguous relationships upon the plastic surface of the foundation layer, so that areas of the latter remain exposed between inlays; applying pressure to impress the inlays into the surface of the foundation la er, and to weld and integrate the two, an to cause part of the foundation layer to flow into spaces between inlays; and governing the pressure to predetermine the relative impressin of the inlays and ofthe foundation ayer, and to disflowin fie areas of the foundation layer bepose t tween inlays ata lower surface level than that of the inlays.

12. The method of making linoleum which be impressed into the foundation; assembling inlays in substantially non-contiguous relationships, upon the plastic surface-portions of the foundation; applying pressure to impress the inlays into the foundation and to produce difierent surface levels of the inlays and such portions of the foundation layer as intervene between inlays, While preserving beneath the inlays collectively a substantially thick stratum of' the foundation material which supplies a strong body for the product independently of the inla s. g

13. The method of making inoleumwhich comprises forming a foundationlayer of linoleum composition of substantial thickness;

and forming inlays; the foundation layer and inlays having surface-portions capable of being welded together and integrated under pressure, and of permitting the inlays to be impressed into the surface of the foundation layer, and permitting surface-portions of the latter to flow somewhat under pressure; assembling inlays in substantially non-contiguous relationships upon the plastic surface of the foundation layer so that areas of the'latter reinainexposed between inlays; applying pressure to predetermine the relative impressing of the inlays and flowing of the foundation layer, and to dispose at difierent surface levels the inlays and the areas of foundation layer between inlays, while preserving beneath the inlays collectively a stratum of the foundation layer material which supplies a substantially integral body for the product independently of the inlays. I

14. As a new article of manufacture, a linoleum comprising a foundation layer of linoleum composition of substantial thickness and homogeneity extending continuously throughout the area of the linoleum; sepa rate inlays of linoleum composition embedded at least partially in the surface of said foundation layer, and welded and integrated therewith, said inlays being positioned in substantially non-contiguous relationship so that portions of the foundation layer are interposed and exposed between the inlays;

the inlays and areas of the foundation layer between inlays being disposed at difierent surface levels; and the foundation layer having a continuous homogeneous stratum ex tending integrally beneath the inlays collectively supplying a strong body for the linoleum independently of the bonds between the inlays and the foundation layer.

15. As a new article of manufacture, a linoleum comprising a foundation layer of linoleum composition; inlays embedded at least partially in the surface of said foundation layer, positioned in substantially noncontiguous relationship so that portions of the foundation layer are interposed and exposed between the inlays; the inlays and areas of the foundation layer between inlays being disposed at different surface levels; and the foundation layer having a substantially thick stratum extending beneath the inlays collectively supplying a strong body for the product.

16. As a new article of manufacture, a linoleum comprising a foundation layer of linoleum composition; separate inlays of linoleum composition embedded at least partially in the surface of said foundation layer, and welded and integrated therewith, said inlays being positioned in substantially noncontiguous relationship, so that portions of the foundation layer are interposed and exposed between inlays; the inlays and areas of the foundation layer between inlays being disposed at different surface levels; and the foundation layer having a stratum extending substantially integrally beneath the inlays.

17. As a new article of manufacture, a linoleum comprising a foundation layer' of linoleum composition; separate inlays of linoleum composition embedded at least partially in the surface of said foundation layer, and welded and integrated therewith, the inlays being in substantially non-contiguous relationship on the foundation layer, so that portions of the latter are interposed and exposed between inlays; the inlays and the areas of the foundation layer between inlays being located at different surface levels; and the projecting portions of the surface of the product being devoid of abrupt corners.

18. A readily-flexible inlaid sheet comprising flexible tesserae of consolidated but relatively soft material and having straight-line edges spaced slightly from each other and only partially embedded into and surfacewelded to an underlying base of similar material, said tesserae being also welded to and standing in relief with respect to integral portions of the base material which extend upwardly between, and the upper surfaces of which are exposed in narrow strips between, said tesserae.

19. The process of producing an inlaid sheet having tesserae in relief which consists in providing a comparatively soft founda tion sheet sufficiently thick to allow tesserm to be embedded therein, preparing previously-consolidated tesserae of the desired shapes and colors, arranging said tesserze on the surface of said foundation sheet in the desired pattern but separated from each other at least such a distance as may benecessary to accomplish the results hereafter specified in this claim, exerting downward pressure upon the exposed faces of said tesserae sufficient to embed them bodily into the base material while at the same time allowing portions of said base material which lie adjacent the tesserae to relatively flow upward between the tesserae, and relieving the pressure before the tesserae are completely embedded, said base material and tesserae material being of such relative consistencies that the pressure exerted upon the tesserae as above described is not suflicient to laterally deform the tesserae enough to close up the spaces between the tesserae or to cause the base material to reach the level of the tesserae faces, whereby there results an inlaid sheet having tesserae in relief with respect to the surface of upwardly-extending portions of the base material which are disposed and exposed to View between the tesserae, the whole forming a substantially integral readily-flexible sheet.

20. The process of producing an inlaid sheet having tesserae in relief, which consists in arranging upon a base of relatively soft material previously-consolidated and shaped tesseree of similar material somewhat spaced from each other, and exerting downward pressure upon the faces of the tesserae sufficient to embed them into the base material and relieving the pressure at such time as leaves sunked areas between the tesserae in which the base material is exposed, whereby, due to various causes such as inaccuracies of tesserae-positioning and irregular lateral expansion of the material, visuallyapparent irregularities of joint width and groove shape are produced which do not necessarily occur on successive pattern-repeat areas.

21. An inlaid sheet of linoleum or the like having consolidated tesserae separated somewhat from each other and embedded in a consolidated but somewhat soft base material and standing in relief with respect to interposed and exposed portions of the base material, and having visually-apparent irregularities of joint width and groove shape which are not necessarily reproduced in successive repeat areas.

Signed at Trenton, New Jersey, this 25th day of July, 1928.

JOHN TOMEC. FRANK OUBRDA.

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